Sound-reducing baffle

ABSTRACT

An accessory to an exhaust system is disclosed which reduces the decibel output from the engine of a vehicle while negligibly affecting the horsepower produced by the engine. The accessory can be built directly into an exhaust system by the manufacturer or added as an after-market enhancement by the consumer. The key elements to the device include a sound-funneling housing which circumscribes a diffusing element, both of which are removably or permanently capped on one side. The uncapped end of the housing is formed to engage a portion of the actual exhaust system. The overall result of this device reduces the total amount of noise produced, without noticeably affecting engine performance, while simultaneously inhibiting harmonic sound waves that can create an annoying rattling sound for the driver or passenger.

FIELD OF INVENTION

The present invention relates to the field of automotive engines. More specifically, the invention relates to exhaust augmentations for automotive engines.

BACKGROUND OF THE INVENTION

As cities and streets become more populated, the number of vehicles on the road constantly increases. Streets grow closer and closer to populated areas, including business districts and residential areas with homes and schools. The pervasiveness of accumulating traffic from cars, trucks and motorcycles on these streets not only impacts the chemical makeup of our environment but also the total amount of ambient noise as well. Gasoline-powered vehicles, in particular, produce a substantial amount of noise and greatly contribute to this type of pollution. In fact, the amount of noise generated from these vehicles accounts for the number one source of noise pollution today.

The noise pollution due to the expanding public and increased number of vehicles interferes with our daily lives and slowly impinges upon our privacy and personal freedoms. But in addition to population growth, and especially in the United States, there exists a particular type of consumer of the automotive industry that demands the greatest amount of power from their ride. Motorcycle and scooter enthusiasts are no exception to this urge to command a powerful engine. In most cases, an increase in horsepower is accompanied by an increase in the decibel level that is produced from an engine. This means that population growth not only affects the total number of vehicles on the road, but also increases the quantity of noise from each vehicle to create a multiplicity effect on the environment and our personal space.

Currently, cars are equipped with mufflers and motorcycles are equipped with exhaust pipes that are regulated by law. For example, many states such as California began requiring each municipality and county to have a Noise Element of the General Plan. But for the most part, noise regulation is enforced by city ordinances, meaning fines. Smog checks are required to be performed to renew any vehicle registration but the level of noise output from a vehicle is not and can not be regularly checked. Testing and enforcement of noise level only occurs in the form of random spot checks and citations from police officers, who in the course of normal business do not carry sound meters.

A few previous solutions have been suggested to alleviate this problem. However, most sound reducing equipment on the market today uses some sort of dampening material in order to muffle sound. For example, U.S. Patent Application No. 20070227811 discloses a vehicle exhaust system containing a sound absorbing material on the outer surface of a side wall of an inner core. Other solutions have involved using devices that actually reduce the amount of horsepower from an engine in order to dampen the sound. Unlike these applications, the presently disclosed device actually obstructs sound in a blocking fashion based on the particular shape and construction of the baffle. It should be noted however that the exact shape of the presently disclosed device varies as it is uniquely created to fit certain size engines and specific model exhaust pipes.

SUMMARY OF THE INVENTION

An accessory to an exhaust system is disclosed which reduces the decibel output from the engine of a vehicle without noticeably affecting the horsepower produced by the engine. The accessory can be built directly into an exhaust system by the manufacturer or added as an after-market enhancement by the consumer. The key elements to the device include a sound-funneling housing which circumscribes a diffusing element, both of which are removably or permanently capped on one side. The uncapped end of the housing is formed to engage a portion of the actual exhaust system. The overall result of this device reduces the total amount of noise produced, without noticeably affecting engine performance, while simultaneously inhibiting harmonic sound waves that can create an annoying rattling sound for the driver and passenger.

These and other objectives of the claimed invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an exploded view of the preferred embodiment of the present invention.

FIG. 2 illustrates a side view of the preferred embodiment of the present invention.

FIG. 3 illustrates a rear three-quarter view of the preferred embodiment of the present invention.

FIG. 4 illustrates a front three-quarter view of the preferred embodiment of the present invention.

FIG. 5 illustrates a rear view of the preferred embodiment of the present invention, showing a diffusing element within the core.

FIG. 6 illustrates a front three-quarter view of the preferred embodiment of the present invention inserted into a typical exhaust pipe with the use of a nut and screw.

FIG. 7 illustrates a front view of one embodiment of the present invention inserted into a typical exhaust pipe with an additional flange directed inward from the proximal end of the core.

FIG. 8 illustrates a front view of one embodiment of the present invention engaged with just the final section of a typical exhaust pipe.

FIG. 9 illustrates a rear view of one embodiment of the present invention, showing a diffusing element within the core being held in place by a rod running through the center of the diffusing element.

FIG. 10 illustrates a rear three-quarter view of one embodiment of the present invention, showing a short imperforated core throat and a flat end cap without any lip or additional flanges.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

In the following description of the various embodiments, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration, various embodiments in which the invention may be practiced. It is to be understood that other embodiments may still be utilized and structural and functional modifications may be made without departing from the scope and spirit of the present invention.

Referring to FIG. 1, an exploded view of the preferred embodiment of device 10 is shown. Device 10 includes insertable core 11 which is attached at one end to end cap 12. Core 11 can be hollow or partially filled along its side walls. In the preferred embodiment of device 10, core 11 is cylindrical in shape but core 11 does not have to maintain a perfect circle in any one plane. For example, the shape of core 11 in the plane normal to the opening of core 11 may be oval, semi oval, contain several straight edges or even be rectangular or octagonal in shape. These various shapes are envisioned in order to fit within certain existing exhaust pipes. They may be crafted so that core 11 fits flush with an exhaust pipe or contains small areas that are open or blocked from the outside air. This allows only a predetermined capacity of gas to flow through device 10. The exact amount of gas passing through device 10, combined with the shape of various components, eliminates harmonic vibrations that can occur from different engine systems. The end of core 11 opposite end cap 12 comprises any number of perforations 14, which allow gases to escape from core 11. Perforations 14 can be manufactured in any size or shape and extend along core 11 stopping short of end cap 12 to reveal the unblemished throat 15 of core 11. These perforations 14 can also be patterned in a particular way or randomly.

Still referring to FIG. 1, device 10 also comprises diffusing element 16, which is usually inserted within core 11 during manufacturing. It can be held in place by being welding to the side walls of core 11 or attached to the side walls by other means that are known in the art, either continually or sporadically along its edges. In the preferred embodiment, diffusing element 16 is rectangular in shape and contains alternating folds so that it is bent in an accordion fashion. The number of folds and distance between folds vary for different systems that work in conjunction with device 10. In other embodiments of device 10, diffusing element 16 may not be rectangular in shape. This will depend upon the specific model of device 10. The sheet of material that forms diffusing element 16 may have different thicknesses at different points along its length. Also, diffusing element 16 may be formed by at least two separate pieces 17 and 18 that fit together to complete the structure.

Now referring to FIG. 2, a side view of device 10 is shown. End cap 12 can more thoroughly be seen in this illustration. End cap 12 is shown comprising locating tab 20, which in turn comprises locating hole 21. In the preferred embodiment, end cap 12 can be fastened around throat 15, as depicted in FIG. 1, by solder. However, in various alternative embodiments, the fastening may be accomplished by other methods known in the art, including but not limited to pressure alone. Additionally, end cap 12 can be secured by adjoining diffusing element 16. It can also be appreciated that perforations 14 may not continue entirely around core 11, in order to leave room for at least one unblemished column 23 along core 11, which provide additional structural support to device 10. End cap 12 may also include a variety of motifs, such as the hollowed dip cup shown in FIG. 2, which incorporates a ring and one beveled lid 24. Alternatively, end cap 12 may contain a lid 24 on both sides and remain hollow or be filled solid. Also, some embodiments will include various design features and ornamental indicia of device 10.

Now referring to FIG. 3, a rear three quarter view of device 10 is shown. This illustration best shows the pervasiveness that perforations 14 can take, almost completing inundating core 11 until merely thin weaves or nets of material 30 remain. In the preferred embodiment of this invention, core 11 would be inserted into an exhaust system beginning with the perforated side (shown on the top of FIG. 3). The material for core 11 may be anything durable and semi heat resistant including, but not limited to, metal, metal alloy, polymer, vulcanized rubber or ceramic. Perforations 14 may end abruptly toward the front of core 11 (shown toward the bottom of FIG. 3) or gradually fade before reaching core throat 15. The effect of the multiple perforations 14 is to further disrupt the flow of gas from device 10. Perforations 14 create surfaces on the interior wall of core 11 which preclude laminar flow. This slows the exhaust gases from jetting out all at once while reducing the total amount of escaping gas which softens the resulting sound.

Now referring to FIG. 4, a front three quarter view of the preferred embodiment is shown. The inside of end cap 12 can more easily be viewed from this angle. The corner where end cap 12 meets core throat 15 may alternatively contain a flange (see FIG. 7) that juts inward in order to block additional gases from escaping. As described infra, flanges can control the total amount of gas emitted from device 10, in addition to reducing the amount of noise to some degree. In this particular illustration, core throat 15 extends into lid 24 to some extent along lip 40. However, lid 24 may not always completely surround core throat 15, or even include lip 40. Also in this illustration, locating tab 20 is shown flush against end cap 12, but in various embodiments, it may be separated from the ring of end cap 12. Additionally, it may be entirely absent if locating hole 21 is found directly on end cap 12.

Now referring to FIG. 5, a rear view of the preferred embodiment of the present invention is shown with diffusing element 16 within core 11. An especially clear view of diffusing element 16 can be gleaned from this angle. As mentioned supra, the preferred shape of diffusing element 16 is rectangular. Its folds can alternate in direction each and every bend, periodically or at random to create the optimum diffusion of gas, which is expelled from a joined exhaust pipe. Even more, the angle of each bend of diffusing element 16 may be in the range from 0-180 degrees. Alternatively, element 16 may be constructed from one or more distinct pieces 17 and 18. In some embodiments, pieces 17 and 18 may traverse the complete width and make contact with core 11. In other embodiments of device 10, element 16 may include protruding members or take any form which blocks the flow of gas in a manner that reduces the decibel output of an adjoining engine (not shown). It can be appreciated that the gases flowing from a typical exhaust pipe discharge in waves as the pistons in the engine fire and compress gases. These waves have frequencies which often reach harmonics that rattle the entire vehicle, besides creating even more noise for bystanders. Thus, by changing the air patterns within core 11, element 16 frustrates these waves so that specific harmonics can not be reached.

Now referring to FIG. 6, a front three-quarter view of the preferred embodiment of the present invention is shown with device 10 inserted and attached to typical exhaust pipe 60 simply with the use of screw 60 and nut 61. From this exterior vantage point, core throat 15 can be visible along with lip 40 of end cap 12. The ring of end cap 12 is shown to be flush with exemplary exhaust pipe 60. Alternatively, in other embodiments of the present invention, a small gap might exist between cap 12 and pipe 60. This particular illustration does not contain any ornamental designs to device 10, but the inventor reserves all rights to obtain various design patents to be used in conjunction with the present invention.

Now referring to FIG. 7, a front view of one embodiment of the present invention is shown inserted into a typical exhaust pipe with additional flange 70 directed inward from the proximal end of the core. Flange 70 is made to cover a portion of the exit from core 11. In this embodiment, flange 70 is rectangular with its broadest face parallel to the side walls of core 11, but it is possible that flange 70 could pivot to block a greater area of the exit. In fact, one side of flange 70 could be shaped in a semicircle in order to fit evenly with the side wall of core 11. Device 10 may also incorporate other obstructions, blockades, barriers and impediments that are known in the art.

Now referring to FIG. 8, a front view of one embodiment of the present invention is shown engaged with just the final section of a typical exhaust pipe. In this particular embodiment, end cap 12 is filled almost completely solid. Drill hole 80 can be bored in exhaust pipe 60 as a possible connection to device 10. Similarly, preexisting hole 81 can also be used as a possible connection to device 10. Also, in this particular embodiment, core throat 15 is larger in diameter than insertable core 11 and a small ridge can be seen slightly partitioning the two distinct pieces.

Now, referring to FIG. 9, a rear view of one embodiment of the present invention is shown with diffusing element 16 within core 11 being held in place by rod 90 running through the center of the diffusing element 16. Optional rod 90 may extend through some or all of element 16 and attach at the proximal end of device 10, preferably to end cap 12. In addition to providing support, rod 90 can perform a stabilizing function when diffusing element 16 is cut thin in order to hinder or prevent vibration through device 10.

Finally, referring to FIG. 10, a rear three-quarter view of one embodiment of the present invention is shown with imperforated throat 15 and flat end cap 12. Either of these two possibilities may exist independently or in combination with any of the other possible variances suggested in this disclosure. From this perspective, it can easily be seen that end cap 12 does not contain a lip directed either inward or outward or any additional flange which would reduce or deflect the amount of gases passing from an exhaust pipe (not shown) through device 10. As such, this simple embodiment of the invention does not usually extend past the opening of an exhaust pipe. The diameter of end cap 12 can be sized to fit any model exhaust pipe and it can be secured in any manner previously suggested. Throat 15 may also contain an additional core structure within it or extending from the end of throat 15. Additionally, throat 15 may be cut short so that it does not extend as far into the mouth of an exhaust pipe. Throat 15 may also be shaped in different patterns which are not necessarily cylindrical and possibly change the direction of gases flowing through throat 15. The tip of diffusing element 16 can also be seen in this figure and be configured or constructed as suggested in this disclosure.

The present invention includes any novel feature or combination of features disclosed herein either explicitly or any generalization thereof. While the invention has been described with respect to specific examples including presently preferred modes of carrying out the invention, those skilled in the art will appreciate that there are numerous variations and permutations of the above described apparatus. Thus, the spirit and scope of the invention should be construed broadly as set forth in the previous specification or appended claims. 

1. A sound-reducing baffle for a gasoline-powered engine comprising: a cylindrical, hollow core with a proximal end and a distal end, said distal end containing a plurality of perforations and constructed to be engaged within an exhaust system; an end cap fixed around said proximal end, said end cap capable of being joined to said exhaust system; and a diffuser inserted within said core and mounted to either said core or said end cap.
 2. The baffle of claim 1, wherein said core is comprised at least partially of one or more materials of the group consisting of metal, metal alloy, polymer, vulcanized rubber and ceramic.
 3. The baffle of claim 2, wherein said core varies in diameter between said proximal end and said distal end.
 4. The baffle of claim 3, wherein said core contains locking mechanisms which removably affix said end cap, said proximal end or said distal end to said exhaust system.
 5. The baffle of claim 4, wherein said end cap is affixed to said exhaust system by means of a locking tab, nail, screw, pin, tack, staple, bolt, catch, clamp, clasp, collar, pressure, adhesive, cement, plaster or solder.
 6. The baffle of claim 1, wherein said proximal end of said core has a diameter greater than the width of said diffuser and less than or equal to the width of said exhaust system.
 7. The baffle of claim 6, wherein said proximal end comprises a flange that juts inward, said flange creating a barrier that reduces any gap between said core and said diffuser.
 8. The baffle of claim 1, wherein said perforations are uniform or non-uniform in size or shape.
 9. The baffle of claim 8, wherein said perforations are located in a regular or randomized pattern.
 10. The baffle of claim 1, wherein said diffuser comprises a rectangular sheet of material which is kinked to form a plurality of bends.
 11. The baffle of claim 10, wherein at least one of said bends alternates in direction from another of said bends.
 12. The baffle of claim 10, wherein said diffuser is mounted to said core or said end cap by means of a central rod that runs through said diffuser.
 13. A sound-reducing baffle to be used in conjunction with a motorcycle exhaust pipe comprising: an obstructing core with a proximal end and a distal end, said distal end containing a plurality of perforations and constructed to be engaged within said exhaust pipe; an end cap fixed around said proximal end, said end cap capable of being joined to said exhaust pipe; a diffuser located within said core and mounted to either said core or said end cap; and a locking tab capable of joining said baffle to said exhaust pipe.
 14. The baffle of claim 13, wherein said obstructing core is hollow.
 15. The baffle of claim 13, wherein said distal end of said core is shaped in a manner that alters the frequency of sound waves traveling through said tailpipe.
 16. The baffle of claim 13, wherein said distal end comprises perforations that are non-uniform in size or shape, said perforations being located in a regular or randomized pattern.
 17. The baffle of claim 13, wherein said distal end of said core is shaped in a manner that reduces the decibel output of sound waves traveling through said exhaust pipe, while negligibly affecting the total horsepower of any vehicle used in conjunction with said exhaust pipe.
 18. The baffle of claim 13, wherein said proximal end, said distal end or said end cap comprises a flange that juts outward, said flange creating a barrier that reduces any gap between said core and said exhaust pipe.
 19. The baffle of claim 13, wherein said diffuser comprises a rectangular sheet of material which is kinked to form a plurality of bends, at least one of said bends alternating in direction from another of said bends.
 20. The baffle of claim 14, wherein said locking tab removably or permanently affixes said end cap, said proximal end or said distal end to said exhaust pipe by means using one or more of the group consisting of: nail, screw, pin, tack, staple, bolt, catch, clamp, clasp, collar, pressure, adhesive, cement, plaster or solder. 